NSK Lubrication Unit NSK K1 - Steven Engineeringstevenengineering.com/Tech_Support/PDFs/NSK_K1.pdf · Lubrication Unit NSK K1. TM › ... lubrication unit equipped on a NSK linear

LUBRICATION UNIT NSK K1TM

USED ON NSK LINEAR GUIDESTM, BALL SCREWS, AND MONOCARRIERSTM

Courtesy of Steven Engineering, Inc. - (800) 258-9200 - [email protected] - www.stevenengineering.com

2

Lubrication Unit NSK K1TM

› NSK K1TM lowers machine operation cost, and reduces impact on the environment.› NSK K1TM is a lubrication device which combines oil and resin in a single unit. The porous resin contains a large amount of lubrication oil. › Touching its surface to the raceway of a rail close to the ball contact point NSK K1TM constantly supplies fresh oil which seeps from the resin.

NSK K1TM lubrication unit equipped on a NSK linear guide, ball screw or MonocarrierTM is an outstanding new lubrication method. A newly developed porous synthetic resin contains large volume of lubricant oil that seeps out and enhances lubricating function.

Magnification of NSK K1TM

100 µm

Portion containing high proportion of polyolefin

Portion containing high proportion of lubricating oil

■ Long-term maintenance-free (cost reduction)■ Long life in severe environments■ Environmentally sound clean lubrication systemLubricant oil and polyolefin combined and molded into one unit■ Containing 70% of lubrication oil■ Supplies lubricant oil for long periods of time (Service

life: in excess of 100,000 hours)

You can achieve the following:

NSK Linear Guides equipped with NSK K1TM

Installation to ball screw

K1 cap

NSK K1

Garter spring

Screw shaft Labyrinth seal

Ball nut

TM

TM

Features of NSK Linear Guides equipped with NSK K1TM

Installation to linear guide Ball slide

Clamping ring

NSK K1

End seal

Protective cover

End cap

Rail

TM

› With the NSK K1TM lubrication unit, maintenance is unnecessary for more than five years or 10,000 km.› Simply attach the unit inside the standard end seal.› The NSK K1TM lubrication unit is also available for use with food machinery, medical equipment and peripherals in environments with strict hygienic or sanitation restrictions. See page 5 for details.

Ball Screws equipped with NSK K1TM


3

Long-Term Maintenance Free (Cost Reduction)

A lubrication system equipped with the NSK K1TM lubrication unit is maintenance free for more than five years or 10,000 kilometers.

› A reduction in expenditure on oil or grease cost by making it unnecessary to replenish lubricants for an extended period› A reduction in personnel costs for regular maintenance› A reduction in the cost of designing and replenishing piping or equipment, parts expenditures, and lead time for assembly› A reduction in the cost for coolants and in processing oil waste (No lubricant contamination = Prolonged life of coolants)

Comparison test between NSK K1TM and standard seal

Conventional systemSupplying oil using a lubrication unit and centralized piping

New lubrication systemUsing the NSK K1TM lubrication unit

NSK K1

Advantages

0 10,000 20,000Running distance, km

with NSK K1TM

No lubricant

30,000 40,000 50,000

Damaged at 79 km

Running 50,000 km(still able to run)

(1) Linear guide

Sample: LH30 (slight preload)Lubrication: 1) Only NSK K1TM

2) No lubricantLoad: NoneSpeed: 60 m/minStroke: 750 mm

Running distance, km


0 5,000 10,000 15,000 20,000 25,000

with NSK K1TM

No lubricant Damaged at 8 km

(2) Ball screw

Sample: Shaft dia. 20 mm, lead 20 mmLubrication 1) Only NSK K1TM

2) No lubricantLoad: NoneSpeed: 40m/minStroke: 450 mm

TM


4

Long Life in Severe Environments

Use of the NSK K1TM lubrication unit significantly prolongs the life of your machinery, even in severe contaminated environments or undesirable environments for lubrication.

› A reduction in maintenance cost, including repair parts and personnel› Longer time between repairs è shortened down-time on the production line è Improved productivity

Test result of ball screws in contaminated environments

Example of severe environments

Advantages

Test result: abrasion on nut grooves of a ball screw (perpendicular surface) (Running distance: 1,864 km)

Sample: Screw shaft dia. 40 mm, lead 10 mmCircuit: 2.5 × 1Lubrication: 1) AS2 Grease (packed before operation only) 2) AS2 Grease (packed before operation only) + NSK K1TM

Load: 3.9 kNSpeed: 2,000 min-1 (20 m/min)Stroke: 340 mmContamination: Dropped contaminants onto screw shaft periodically. FCD45 particle 115 MESH added at coolant

(Coolant dilution 30:1) Volume of contaminant: Coolant 3,600 cm3 + casting particles

1.8 g/day

0 0.5 1.0 1.5 2.0 2.5 3.0－20－15－10－505101520

µm

mm0 0.5 1.0 1.5 2.0 2.5 3.0

－20－15－10－505101520

µm

mm

(1) Without NSK K1TM (2) With NSK K1TM

Abrasion higher than 20 µm (when abrasion is spread all over the grooves)

Abrasion around 5 to 6 µm (normal abrasion conditions)

› Contaminated environments: machine tools, welding machines, etc. › Environments where oil and grease absorbing dust is produced: woodworking machines, textile machines, papermaking machines, printing

machines, etc.› Environments where lubricant is washed away: machines that are washed away entirely by water, machines that are exposed to rain or

water.

Note: Rust preventive treatment is required for corrosive environments.

Use of the NSK K1TM lubrication unit has reduced abrasion of ball screws by 75%.


5

Environmentally Sound Clean Lubrication System

By using the NSK K1TM lubrication unit, you can solve these problems and achieve a clean and environmentally sound machinery /equipment system.

› Suitable for machinery or equipment used where exposed lubricants should be avoided, such as food processing machinery, medical equipment, or engineering and textile machinery.

› Suitable for machinery or equipment that requires extremely high levels of cleanliness, such as semiconductor and LCD fabrication-related equipment.

› Improvement of work environment.

Precautions for handling

Adjacent areas for NSK K1TM installed linear guide

Merit

NSK K1TM installed linear guideReplenishing grease is not required, so machines are kept clean.

To maintain high functionality of the NSK K1TM, observe the following precautions:1. Temperature range for use: Maximum temperature in use: 50°C

Momentary maximum temperature in use: 80°C2. Chemicals that should not come into contact with NSK K1TM: Do not leave the NSK K1TM in an organic solvent, such as hexane and thinner that remove oil, or rust preventive

oil that contains white kerosene.

Note: Water-type cutting oil, oil-type cutting oil, mineral-oil type grease and ester-type grease do not damage NSK K1TM.


6

› The NSK K1TM lubrication unit for food processing and medical equipment is a phenomenal new material seal that is safe and secure.

› The newly developed porous synthetic resin contains abundant lubricant.

› With the basic functions of highly praised NSK K1TM for general industry, more sophisticated materials make it applicable in food and medical equipment.

› It also offers easy installation, mounted inside the standard end seal (rubber).

Features of NSK K1TM Lubrication Unit for Food and Medical Equipment

Features of NSK Linear Guides for Sanitary Environments

NSK Linear Guides for Food Processing and Medical Equipment in Sanitary Environments

The NSK K1TM lubrication unit for food processing and medical equipment is safe and secure. NSK K1TM FDA-compliant material is used for the lubrication unit, so it is used without concern for food processing and medical equipment.

› Very safe to handle: Uses highly safe materials that are compliant with the US Food and Drug Administration's (FDA) hygiene standards for food additives.

› Environmentally sound: The newly developed porous synthetic resin provides a controlled supply of lubricant, preventing the dispersion of oil in sanitary

environments.

› Resistant to harsh environments: It is durable not only under normal environments, but also under harsh environments, such as machinery submersed in water.

› The highest grade of category H1 grease of USDA standard is used for NSK K1TM lubrication unit.*category H1: Lubricants permitted for use where there is possibility of incidental food contact*USDA: USDA (The United States Department of Agriculture)

› Features of grease for food processing machines:■ This grease is approved by USDA H1. (National Science Foundation [NSF] carries out certification for USDA.)■ Superb water resistance and antirust capability■ Superb wear resistance■ Applicable for a centralized oiling system

› Appropriate volume of grease:A supply of appropriate volume of grease reduces grease draining and scattering, and maintains a clean environment.

The table below shows available models.

NH Series NH12, NH15, NH20, NH25, NH30, NH35

NS Series NS15, NS20, NS25, NS30, NS35

LW Series LW17, LW21, LW27, LW35

PU Series PU09, PU12, PU15

LU Series LU09, LU12, LU15

PE Series PE09, PE12, PE15

LE Series LE09, LE12, LE15


7

Introduction of Performance by Use:Automotive Manufacturing Equipment

Maintenance Free, Long Life even in Severe Environments

Merit

Applications

Actual results from welding machines, the most severe environment in automotive plants

Operating conditions:Sample: LH300200ELC1-PCZ No.1: Double seal + Protector (no NSK K1TM) No.2: NSK K1TM attached + Single seal + ProtectorTested on the same welding machine at the same place in automotive production line Sample No. 1: 10.5 month operation Sample No. 2: 13 month operation

Comparison after running:Sample No. 1 (without NSK K1TM):

Rail and ball slide raceways and balls showed rust and extensive deterioration

Sample No. 2 (with NSK K1TM):Rail and ball slide raceways and balls had no rust and only slight deterioration

› Reduced expense for lubricants (see graph to the right)

› No oil or grease supply systems required Reduced equipment cost

› Improved machine design time and efficiency No piping design required

› Long-term maintenance free Reduced maintenance cost

› Better for the environmentNSK K1TM reduces lubricant consumption, minimizes waste oil

Ball deterioration

Sample No. 1(without NSK K1TM)

Sample No. 1(without NSK K1TM)

Sample No. 2 (with NSK K1TM)

Sample No. 2(with NSK K1TM)

Rail raceway deterioration

35,000

30,000

25,000

20,000

15,000

10,000

5,000

0

Lubr

ican

t vol

ume,

cm

3

0.3 cm3 × 16 hr/day× 340 days/year × 5 years× 4 slides＝32,640 cm3

59 cm3 × 4 slides＝236 cm3

NSK K1TM with grease Oil lubrication

Comparison of lubricant consumption

Estimated oil consumption in the test equivalent to 5 years running (for 4 LH45 slides)

› Lifter and carrier › Multi-tier stock systems › Sorting systems › Engine/chassis decking systems › Underbody line welding machines › Body line conveyor systems › Marking machines › Assembly machines› Material handling systems › Differential gear grinding machines› Assembly vibration testers


8

Applications› Machining centers › NC Lathes › Water jet cutter› Pallet changer › Laser processing machines (X and Y axes) › Telescopic cover for horizontal machining center

High-Load Life Test Using Cutting Coolant which is Contaminated with Cast Iron Particles

3 samples of different lubricant conditionsTest conditions:Sample: LY45BN (Preload Z4)Load: 9,800 N per one ball slidePreload: 4,400 N Grease: AV2Feed: Average 24 m/min Stroke: 400 mmContamination: Coolant dilution 30:1 FCD45 particles 115 MESH (125 µm or less) added at 5% (by weight)Pattern: 2 days in coolant (ball grooves of rail are immersed), 5 days no coolant

40,000

35,000

30,000

25,000

20,000

15,000

10,000

5,000

0

NSK K1TM with grease

Oillubrication

Lubr

ican

t vol

ume,

cm

3

0.45 cm3 × 16 hr/day× 250 days/year × 5 years× 4 slides＝36,000 cm3

48 cm3 × 4 slides＝192 cm3

Comparison of lubricant consumptionEstimated oil consumption in the test equivalent to 5 years running (for 4 LA45 slides)

Friction force change150

100

50

00 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000

Fric

tion

forc

e, N


No.1 No.2 No.3

Test results

Sample Lubricating condition (*1)

Condition ResultDistance (km)

Running year (*2)Broken end

capFlaking Lost

Preload

No.1 Grease onlyYesTest stopped

No Yes

End cap broke prematurely due to inadequate means of lubrication and particles. 600 km, 0.8 years.

No.2NSK K1TM (4 pcs.)+ Grease

No No No Running uninterrupted over 3,600 km, 5 years.

No.3 Oil only No Slight Yes

Shortened life because of particle and inadequate means of lubrication. 3,000 km, 4.1 years.

(*1): No replenishment of grease to sample No.1 and No.2 during test.(*2): Running year is calculated by 720 km/year (average 3 m/min × 16 hr/day × 250 days/year).

› Reduced expense for lubricants (see graph to the right)



› Better for the environment NSK K1TM reduces lubricant consumption, minimizes waste oil

Merit

Introduction of Performance by Use:Machine Tools


9

Applications

Long Life even with Wood Chip Contamination

Merit



› Better for the environment NSK K1TM reduces lubricant consumption, minimizes waste oil

Test results (high volume of chips) Test results (medium volume of chips)

Running test in wood chips

Wood chips

NSK K1TM

Standarddoubleseal

0 1,000 2,000 3,000 4,000 5,000 6,000

Damaged at 2,500 km

Damaged at 1,000 km

Running distance, km Running distance, km

0 1,000 2,000 3,000 4,000 5,000 6,000

NSK K1TM

Standarddoubleseal

Damaged at 5,900 km

Damaged at 2,800 km

Comparison test between NSK K1TM and standard double seal

Test conditions:Sample: LH30AN (Preload Z1) Feed rate: 20 m/minStroke: 400 mmLubrication: Standard double seal - AV2 grease NSK K1TM - NSK K1TM + AV2 grease

Load: 490 N per one ball slideWood chip contamination: Set the product in the box with bottom area A, then

put 240 g of wood chips on the rails. Reapplied removed wood chips to rails 3 times/day.

[High volume of chips]: A = 145 mm (width) × 700 mm (length)

[Medium volume of chips]: A = 170 mm (width) × 700 mm (length)

Introduction of Performance by Use:Woodworking Machines

› Router › Lumber cutting, groove making machines › Pre-cutting machines › Unmanned lumbering machines

Life is 2 times longer than standard double seals in woodworking machines


10

Low Particle Emission

High Performance Lubrication - Maintenance free

Good Operability (Stable Dynamic Friction Force)

Applications

Combining the NSK K1TM with LG2 grease for low particle emission is comparable to using vacuum grease.

Test conditions:Sample: LS20Speed: 36 m/min

Over 30,000 km running with only NSK K1TM.

Improved performance can be expected when used with the LG2 Grease.

Dynamic friction force is 1/3 of fluorine type grease (at 20 m/min).

Test conditions:Sample: LS20ALPreload: Z1

Change of dynamic friction force (100% at the beginning)

› LCD substrates polishing machines› LCD glass substrates transporting machines› LCD glass substrates testing equipment› Thin film processing equipment for semiconductors› Washing machines› Full automatic wafer mounters› Washing section of the wafer polishing machines› Carrier arm section of logic handler› CMP

100,000

10,000

1,000

100

100 20 40 60 80 100 120 140 160

Part

icle

cou

nt (s

ize

0.5

µm o

r lar

ger)

Vacuum grease

Time, hr

NSK K1TM+LG2 Grease

NSK K1TM+general grease

Fric

tion

forc

e, N

25

20

15

10

5

0

Speed, m/min

0 5 10 15 20 25

Fluorine type grease

NSK K1TM+LG2 grease

1009080706050403020100

0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000

Chan

ge ra

tio, %


Sample: LH30ANInstalled NSK K1TM with no greaseNo NSK K1TM, AV2 grease lubricated

0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000

NSK K1TM

(middle speed)

NSK K1TM

(middle speed)

NSK K1TM

(high speed)

No NSK K1TM

No lubrication(high speed)





Damaged at 79 km

Z1

Z3

Z1

Z1

Preload

Endurance test without additional lubricationTest conditions:Sample: LH30ANPreload: Z1, Z3

High speed test Medium speed testSpeed: 200 m/min 60 m/minStroke: 1,800 mm 750 mmLoad: 63 N/1 ball slide None

Introduction of Performance by Use:Semiconductor / LCD Manufacturing Equipment

Comparison of particle emission characteristics


11

ApplicationsGood Operability (Stable Dynamic Friction Force)

Keeps Equipment and Adjacent Areas Clean

Wear life is 3 times longer than normal seals under wet conditions.

Change of oil supply of NSK K1TM and dynamic friction force

Test conditions:Sample: LH30AN, preload Z1 (only with NSK K1TM )Stroke: 800 mmSpeed: Average 38.4 m/minLoad: None

› Sample preparation systems› Blood analyzer› Medical examination tables and bed transfer equipment› Medical scanner› Analytic equipment› Food processing machines› Food conveyor

Endurance test in water

Test conditions:Sample: LS30 stainless steelPreload: Z1Load: 4,700 N per one ball slideStroke: 400 mmSpeed: 24 m/minLubrication: Grease full pack (Consistency: 280,

Viscosity: 580 cst)Water exposure: Run in water 1 day per week.

Supp

lied

quan

tity

of o

il in

NSK

K1TM

, %

8

7

6

5

4

3

2

1

00 1,000 2,000 3,000 4,000 5,000 6,000 7,000

20

18

16

14

12

10

8

6

4

2

0

Dyna

mic

fric

tion

forc

e, N


Oil supplyDynamic friction forceDegreased end caps, ball slide and rail

Introduction of Performance by Use:Food Processing, Medical Equipment


0 500 1,000 1,500 2,000 2,500 3,000

End cap damaged at 2,700 km

Wear on rail groove

2,700 km completed(still able to run)

Standard double seal

NSK K1TM

+ Standard seal

Rusted inside ball slideWear on rail groove


K1/AB/1M14. Printed in the USA © NSK 2014. The contents of this publication are the copyright of the publishers.

NSK Ltd. Headquarters, Tokyo, Japan www.nsk.comAsia Business Strategic Division-Headquarters tel: 81-03-3779-7145Industrial Machinery Bearings Division-Headquarters tel: 81-03-3779-7227Automotive Division-Headquarters tel: 81-03-3779-7189Needle Roller Bearings Strategic tel: 81-03-3779-2563 Division-HeadquartersPrecision Machinery & Parts tel: 81-03-3779-7219Division-Headquarters

AfricaSouth Africa:NSK South Africa (Pty) Ltd.Johannesburg tel: 27-011-458-3600

Asia and OceaniaAustralia:NSK Australia Pty. Ltd. www.nskaustralia.com.auMelbourne tel: 61-03-9764-8302

China:NSK Hong Kong Ltd.Hong Kong tel: 86-2739-9933Kunshan NSK Co., Ltd.Kunshan Plant tel: 86-0520-730-5654Changshu NSK Needle Bearing Co., Ltd.Jiangsu Plant tel: 86-0512-5230-1111Guizhou HS NSK Bearings Co., Ltd.Anshun Plant tel: 86-0853-3521505NSK Steering Systems Dongguan Co., Ltd.Dongguan Plant tel: 86-0769-262-0960 Zhangjiagang NSK Precision Machinery Co., Ltd.Jiangsu Plant tel: 86-0512-5867-6496Timken-NSK Bearings (Suzhou) Co., Ltd.Jiangsu Plant tel: 86-0512-6665-5666NSK China Technology CenterJiangsu tel: 86-0512-5771-5654NSK (Shanghai) Trading Co., Ltd.Shanghai tel: 86-021-6235-0198Beijing tel: 86-010-6590-8161Guangzhou tel: 86-020-3786-4833Anshun tel: 86-0853-3522522Chengdu tel: 86-028-8661-4200Shenzhen tel: 86-0755-25904886Changchun tel: 86-0431-8988682NSK (China) Investment Co., Ltd.Shanghai tel: 86-021-6235-0198

India:Rane NSK Steering Systems Ltd.Chennai tel: 91-044-274-66002NSK Ltd. India Branch OfficeChennai tel: 91-044-2446-6862

Indonesia:PT. NSK Bearings Manufacturing IndonesiaJakarta tel: 62-021-898-0155PT. NSK IndonesiaJakarta tel: 62-021-252-3458

Korea:NSK Korea Co., Ltd. www.kr.nsk.comSeoul tel: 82-02-3287-0300Changwon Plant tel: 82-055-287-6001

Malaysia:NSK Bearings (Malaysia) Sdn. Bhd.Kuala Lumpur tel: 60-03-7722-3372NSK Micro Precision (M) Sdn. Bhd.Malaysia Plant tel: 60-03-961-6288

New Zealand:NSK New Zealand Ltd. www.nsk-rhp.co.nzAuckland tel: 64-09-276-4992

Philippines:NSK Representative OfficeMakati City tel: 63-02-893-9543

Singapore:NSK International (Singapore) Pte Ltd.Singapore tel: 65-6496-8000NSK Singapore (Pte) Ltd. www.nsk-singapore.com.sgSingapore tel: 65-6496-8000

Taiwan:Taiwan NSK Precision Co., Ltd.Taipei tel: 886-02-2509-3305

Thailand:NSK Bearings (Thailand) Co., Ltd.Bangkok tel: 66-02-6412-150SIAM NSK Steering Systems Co., Ltd.Chachoengsao tel: 66-038-522-343~350NSK Asia Pacific Technology Center (Thailand) Co., Ltd.Chonburi tel: 66-038-454631~454633

Vietnam:NSK Representative OfficeHanoi tel: 84-04-935-1269

EuropeNSK Europe Ltd. (European Headquarters) www.eu.nsk.comMaidenhead, U.K. tel: 44-01628-509800

France:NSK France S.A.SParis tel: 33-01-30-57-39-39

Germany:NSK Deutschland GmbHDüsseldorf tel: 49-02102-481-0NSK Steering Systems Europe Ltd.Stuttgart tel: 49-0771-79082-277Neuweg Fertigung GmbHMunderkingen tel: 49-07393-540

Italy:NSK Italia S.p.A.Milano tel: 39-02-995-19-1Industria Cuscinetti S.p.A.Torino Plant tel: 39-0119824811

Netherlands:NSK European Distribution Centre B.V.Tilburg tel: 31-013-4647647

Poland:NSK Polska Sp. z.o.o. Warsaw Branch tel: 48-022-645-1525NSK Iskra S.A.Kielce tel: 48-041-366-6111NSK European Technology Center, Poland OfficeKielce tel: 48-041-366-5812

Spain:NSK Spain S.A.Barcelona tel: 34-093-289-27-63

Turkey:NSK Rulmanlari Orta Dogu Tic. Ltd Sti tel: 90-0216-442-7106

United Kingdom:NSK Bearings Europe Ltd.Peterlee Plant tel: 44-0191-586-6111NSK European Technology CentreNewark tel: 44-01636-605123NSK UK Ltd.Newark tel: 44-01636-605123NSK Steering Systems Europe Ltd.Coventry tel: 44-024-76-337100

North and South AmericaNSK Americas, Inc. (American Headquarters)Ann Arbor tel: 1-734-913-7500

Argentina:NSK Argentina SRLBuenos Aires tel: 54-011-4762-6556

Brazil:NSK Brasil Ltda. www.br.nsk.comSão Paulo tel: 55-011-3269-4700

Canada:NSK Canada Inc. www.ca.nsk.comToronto tel: 1-905-890-0740

Mexico:NSK Rodamientos Mexicana, S.A. de C.V. www.mx.nsk.comMexico City tel: 52-55-36822900

United States of America:NSK Corporation www.nskamericas.comAnn Arbor tel: 1-734-913-7500NSK American Technology CenterAnn Arbor tel: 1-734-913-7500NSK Precision America, Inc. www.nskprecision.comFranklin tel: 1-800-255-4773NSK Steering Systems America, Inc. www.nssa.nsk.comBennington, Vermont tel: 1-802-442-5448NSK Latin America, Inc. www.la.nsk.comMiami tel: 1-305-477-0605

Worldwide Sales Offices

NSK Ltd. has a basic policy not to export any products or techology designated as controlled items by export-related laws. When exporting the products in this brochure, the laws of the exporting country must be observed. Specifications are subject to change without notice and without any obligation on the part of the manufacturer. Every care has been taken to ensure the accuracy of the data contained in this brochure, but no liability can be accepted for any loss or damage suffered through errors or omissions. We will gratefully acknowledge any additions or corrections.


Documents

NSK Lubrication Unit NSK K1 - Steven Engineeringstevenengineering.com/Tech_Support/PDFs/NSK_K1.pdf · Lubrication Unit NSK K1. TM › ... lubrication unit equipped on a NSK linear